Polypropylene blends for non-woven production

ABSTRACT

Polypropylene resin compositions are provided that are useful in the production of thermoformed articles and biaxially oriented polypropylene films (BOPPs), tapes and fibers. The resins of the present invention are blends of high crystalline (low solubles) polypropylene homopolymer and an ethylene/propylene random copolymer (RCP). These blends can be used to replace standard high solubles BOPP grade polypropylene homopolymers. In addition, the use of high crystalline polypropylene homopolymers in the blends imparts improved stiffness to the finished films while maintaining good processability of the blends. Such polypropylene compositions are effectively produced by in-reactor blending of a high crystalline propylene homopolymer and a propylene/ethylene random copolymer.

RELATED APPLICATIONS

This application is a Continuation-in-Part of prior patent application Ser. No. 11/110,006 filed on Apr. 20, 2005, now U.S. Pat. No. 7,714,710, which is a Continuation-in-Part of prior patent application Ser. No. 10/786,189 filed on Feb. 25, 2004, now U.S. Pat. No. 7,282,539, which is a Divisional of prior patent application Ser. No. 10/228,487 filed on Aug. 27, 2002, now U.S. Pat. No. 6,733,898.

FIELD OF THE INVENTION

The present invention is drawn generally to the field of polypropylene blends. More specifically, the present invention is drawn to polypropylene blends for production of non-woven fabrics.

BACKGROUND OF THE INVENTION

In the production of non-woven fabrics, such as spunbond and meltblown fabrics, molten polymer is extruded through a many holed die, or spinneret. The fibers are drawn by an air current and then collected in a random array to form a web of fibers. The web thus formed is then bonded by heating it to soften the polymer fibers and then passing the web through smooth or engraved calendar rollers to bond the fibers. Bonding improves the strength of the non-woven fabric over non-bonded materials.

In many cases, the bonding process governs the speed at which a producer can run a line producing non-woven fabrics. The time that the web requires between the nips in the calendaring process is controlled by the properties of the polymer in the fibers that make up the web, as well as the temperature and pressure of the calendar rolls.

In certain applications it is desirable to combine one or more webs of non-woven fabric. Typical constructions of this type combine one or more webs of spunbond fabric with a web of meltblown fabric. Such constructions are termed spunbond-meltblown (S-M) and spunbond-meltblown-spunbond (S-M-S) fabrics. A problem arises in the bonding process for such constructions stemming from the relatively high temperatures needed to bond the spunbond material. These temperatures may cause partial melting of the much finer fibers that make up the meltblown web, resulting in pinholes which compromise the barrier properties of the fabric.

It is known that a PP having a high level of solubles can improve process performance in non-woven fabrics, providing lower bonding temperatures and a wider bonding window. However, as with the production of polypropylene for BOPP films, it is a burden to PP manufacturers to produce high solubles because large amounts of unwanted wide-spec materials are generated to reach targeted high solubles. Also, it is known that the solubles are responsible for smoke generation during fiber spinning.

BOPP (biaxially oriented polypropylene) film is produced by drawing a cast sheet of polypropylene in two directions at a temperature below the melting temperature of the resin. Specific characteristics are required for the standard polypropylenes used to produce BOPP materials, such as relatively larger amounts of xylene solubles, and relatively low isotacticity. It is known that for a given PP, the lower the isotacticity, the lower the melting temperature of the PP and the better its processability to BOPP film. However, these same properties in the PP result in poorer properties of the resulting film. Therefore, there exists a processability-property trade-off in BOPP materials. In addition, production of high solubles materials generally used for BOPP films is not easy because it requires a specific catalyst system and careful handling of powder. It is known that it is difficult to produce a homopolymer containing xylene solubles fractions higher than 6% because a specific catalyst system as well as careful handling of polymer powder in the reactor are required. In general, the large amounts of xylene solubles in the polypropylene become sticky and often cause agglomeration of polymer powder in the reactor, disrupting continuous production at the plant.

To avoid the problems of producing high solubles material, blends that improve the processability of low solubles material have been investigated for BOPP film. It is well known that isotactic PP (iPP) produced by a Ziegler-Natta (ZN) catalyst has a broad isotacticity and molecular weight distribution, thus exhibiting a broad melting temperature range. Conversely, PP produced by a metallocene catalyst exhibits narrow isotacticity and molecular weight distribution and thus, the melting temperature range is relatively narrow. Unlike PP produced by ZN catalyst, some degree of regio-mis-insertion, i.e., “head-to-head” or “tail-to-tail” insertions, of monomer exists in the metallocene isotactic PP (m-iPP). The melting temperature of m-iPP is also affected by the degree of regio-mis-insertion in addition to isotacticity. Thus, an iPP of much lower melting temperature than conventional ZN-iPP can be produced with a metallocene catalyst. When employed in BOPP film, however, a much narrower temperature window for drawing is available due to the narrow tacticity and molecular weight distribution.

The effect of the addition of m-iPP to ZN-iPP on BOPP film was explored by Phillips et al, J. of Applied Polymer Science, 80, 2400 (2001). It was found that the addition of m-iPP to ZN-iPP provides a balance of elevated temperature draw performance and room temperature film properties relative to the ZN-iPP materials. Improved processability of the BOPP film including fewer webs breaks and drawability at higher line speeds have been claimed by the addition of some amounts of metallocene syndiotactic PP to ZN-iPP in U.S. Pat. No. 6,207,093 to Hanyu, Mar. 27, 2001, Fina Technology. The addition of some amounts of modifier tends to improve processability of iPP and/or properties of the resulting film. The selection of the modifier depends on the desired film properties and availability of modifier.

In U.S. Pat. No. 5,691,043, to Keller et al addition of various atactic and syndiotactic polypropylenes, as well as various propylene copolymers to a standard BOPP grade isotactic polypropylene homopolymer to produce a core layer for multi-layer a uni-axially shrinkable film are discussed. However, Keller does not discuss the possibility of replacing standard BOPP grade polypropylene homopolymers with low soluble content material.

In addition to seeking replacements for high solubles polypropylenes, BOPP film manufacturers have long sought a material that provides a stiffer oriented film while maintaining acceptable stretchability. High crystalline PP materials impart the desired stiffness to the finished articles, however, these materials are generally not suitable for processing into BOPP films. This poor operability of high crystalline materials is reported in U.S. Pat. No. 5,691,043.

Previously in related U.S. Pat. No. 6,733,898 the inventors disclosed blends of highly crystalline propylene homopolymer with an ethylene/propylene random copolymer and BOPP films produced using those blends. Blends according to the invention demonstrated good processability in BOPP films and imparted desired characteristics to the finished film in terms of stiffness.

It would also be desirable to provide a polypropylene material for non-woven fabrics that provides the wide bonding window and low bonding temperatures of a high solubles material without the drawbacks of large amounts of off-spec material and increased smoke generation in processing. It would further be desirable to provide a polypropylene material for producing non-woven fabrics that avoids the problems associated with producing high soluble content PP homopolymers. It would further be desirable to provide a process for producing a blend of high crystalline polypropylene homopolymer with a propylene copolymer by in reactor blending.

SUMMARY OF THE INVENTION

The present invention provides a non-woven fabric comprising at least one layer of fibers comprising a reactor blended polypropylene copolymer. The polypropylene copolymer blend comprises about 70% to about 95% by weight of a polypropylene homopolymer, that has less than 3% by weight xylene solubles and a crystallinity of at least 55%. The copolymer further comprises about 5% to about 30% by weight of an ethylene/propylene copolymer, said ethylene/propylene copolymer containing from about 0.5% to about 7.0% ethylene by weight, preferably from about 2% to about 4% by weight.

Preferably, the polypropylene copolymer blend comprises about 70% to about 90% by weight of the propylene homopolymer, and about 10% to about 30% by weight of the ethylene/propylene copolymer. More preferably, the polypropylene copolymer blend comprises about 82% to about 88% by weight of the polypropylene homopolymer and about 12% to about 18% of the ethylene/propylene random copolymer.

The present invention also provides a non-woven fabric produced from the polypropylene copolymer blend of the invention. The non-woven fabric according to the current invention may be either a spunbond or meltblown fabric. In a preferred embodiment according to the invention a multilayer construction is provided comprising at least one layer of spunbond fabric and at least one layer of meltblown fabric. At least one of the layers comprises the reactor blended copolymer according to the current invention. Preferably, at least the spunbond layer comprises the reactor blended copolymer according to the current invention.

The present invention also provides a process for producing blends of highly crystalline, non-BOPP grade, polypropylene homopolymers with ethylene/propylene random copolymers in-reactor. The compositions comprise from about 70% to about 95% of a highly crystalline, non-BOPP grade, polypropylene homopolymer and from about 5% to about 30% of an ethylene/propylene random copolymer. The blends allow the use of polypropylene homopolymers having a higher crystallinity (lower solubles content) than would otherwise be necessary for processing into BOPP films and/or non-woven fabrics.

The compositions according to the current invention can be produced by melt blending of separate resin powders as well as by the in situ in-reactor blending process during production of the polymers. However, the production of these polymers by in-reactor blending allows for more efficient use of reactor capacity, as the in-reactor blending process can make use of the full capacity of a two-stage reactor train. This provides a higher production rate of the polymer blend versus the melt blending process. It also avoids the separate step of blending two separately produced polymers. The in-reactor blending process also results in better dispersion of the random copolymer in the homopolymer, and thus a more homogeneous product.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the T.M. Long Yield Stress of various compounds as a function of temperature.

FIG. 2 shows the T.M. Long yield stress stretched at 280 and 290° F. as a function of cast sheet density.

FIG. 3 shows the thermal fractionation endotherms of HCPP (FF050HC) and its blend with 30% RCP in comparison to FF029A (31J026).

FIG. 4 shows the T.M. Long Yield Stress of various compounds as a function of temperature.

FIG. 5 shows the T.M. Long yield stress stretched at 280 and 290° F. as a function of cast sheet density.

FIG. 6 shows the Tensile Stress of films made from various resins.

FIG. 7 shows the Tensile Modulus of films made from various resins.

FIG. 8 shows the Haze of films made from various resins.

FIG. 9 shows the % Transmittance of films made from various resins.

FIG. 10 shows the 45 degree gloss of films made from various resins.

FIG. 11 shows the Shrinkage of films made from various resins.

FIG. 12( a) shows the tensile strength of various spunbond fabrics in the machine direction (MD).

FIG. 12( b) shows the tensile strength of various spunbond fabrics in the transverse direction (TD).

FIG. 13( a) shows the trapezoid tear strength of various spunbond fabrics.

FIG. 13( b) shows the flexural rigidity of various spunbond fabrics.

FIG. 13( c) shows the coefficient of friction (COF) for various spunbond fabrics.

FIG. 14 shows the tensile strength of various spunbond fabrics in the machine direction and transverse direction.

DETAILED DESCRIPTION OF THE INVENTION

The resin compositions according to the current invention are blends of highly crystalline, non-BOPP grade polypropylene homopolymers and ethylene/propylene random copolymers. The blends according to the current invention may be produced either by melt blending separate powders or by producing the blend in situ in an in reactor process. In either case, the blends according to the current invention display processing characteristics that are comparable to or better than standard BOPP or non-woven grade polypropylene homopolymers. Non-woven fabrics made with the blends according to the current invention display a bonding window in calendaring that is comparable to standard non-woven grade polypropylenes. The non-woven fabrics according to the current invention also display a better balance of properties, such as tensile strength, in the machine direction (MD) and transverse direction (TD). Further, non-woven fabrics according to the current invention display a higher coefficient of friction (“COF”) than fabrics made with standard non-woven grade polypropylenes. In general, the COF is used as a measure of softness for a fabric. Additionally, films made with resins according to the current invention display improved qualities in terms of haze, gloss and stiffness over films produced using standard BOPP grade polypropylene homopolymers.

The resin compositions according to the current invention are useful in the production of non-woven fabric constructions comprising multiple layers of non-woven fabrics. Particularly, the polypropylene blends according to the current invention are useful in multilayer fabrics such as spunbond-meltblown (S-M), and spunbond-meltblown-spunbond (S-M-S) constructions.

Suitable melt flow rates for spunbond fiber processing range from about 8 dg/min to about 55 dg/min as determined using ASTM method D-1238. Polypropylene blends according to the current invention having a suitable melt flow rate for spunbond fiber processing can be obtained by using known methods, such as by regulating melt flow rate using hydrogen, to produce a reactor material of the proper melt flow. Alternatively, a low melt flow rate blend according to the current invention may be produced and then adjusted using controlled rheology techniques to produce a final material having a melt flow rate suitable for spunbond processing. Further, it will be recognized that controlled rheology materials may be pelletized for shipment to processors, or the controlled rheology treatment may be completed by a processor directly prior to fiber production. It will be recognized by those of ordinary skill in the art that the present invention is not limited to a particular melt flow range or means of achieving a particular melt flow rate.

Films comprising the resins according to the current invention can be made by any commercial process for producing films comprising standard BOPP grade homopolymers. For example, two prevalent commercial processes for producing oriented films are the tenter frame process and the “bubble” or blown film process.

In a typical tenter frame process, molten polymer is supplied to a flat slot die, from which a cast sheet or film is extruded. This cast sheet or film is then conveyed to a chill roller where it is cooled to a suitable temperature. The cast sheet or film is then conveyed to a pre-heat roller where it is heated to an appropriate stretching temperature. Stretching in the machine direction is accomplished by means of a pair of sequential rollers. The first, slow roller is followed by a second fast roller that rotates at a speed sufficient to generate a surface speed that is typically 4-7 times faster than the slow roller. The speed differential between the fast and slow rollers causes a 4-7 fold stretching of the cast sheet or film in the machine direction. After stretching in the machine direction, the film is then cooled again by additional chill roller(s) before being conveyed to a second pre-heat roller where it is heated to an appropriate temperature for stretching in the transverse direction. The transverse stretching section of the tenter frame then stretches the film by means of a plurality of tenter clips, which grasp the opposite sides of the film and stretch it in a lateral direction. The concluding portion of the stretching process may include an annealing section. After chilling to an appropriate temperature the film is then trimmed of waste and then applied to take up spools.

The typical steps involved in the bubble or blown film process include extruding the molten polymer is through an annular die and quenching in water to form a calibrated tube. The tube is then conveyed to the orientation tower where it is reheated to the optimum temperature for orientation. At the top of the tower, the tube is squeezed airtight by the first stretching nip. The tube is then heated and inflated with high-pressure air to form a large diameter bubble. The bubble orients the film in the transverse direction while simultaneously, the bubble is stretched in the machine direction by the speed differential between the first and second stretching nips. The oriented bubble is then collapsed by converging rolls and then annealed. After annealing, the film is slit into two webs. Each web is corona treated or flame treated and then wound.

Those skilled in the art will recognize that these examples of a tenter frame and bubble process are for illustrative purposes only. Variations on either process are within the knowledge of one skilled in the art and are considered to be within the scope of the present invention. Further, films produced using the resin compositions according to the current invention are not limited to those produced by either the tenter frame or bubble process. The resin compositions according to the current invention are useful in the production of BOPP films generally and are not limited to the specific methodology disclosed herein.

The resin compositions according to the current invention comprise from about 70% to about 95% of a low solubles polypropylene homopolymer and from about 5% to about 30% of an ethylene/propylene random copolymer. Preferably, the resin compositions according to the current invention comprise from about 70% to about 90% of a low solubles polypropylene homopolymer and from about 10% to about 30% of an ethylene/propylene random copolymer (RCP), even more preferably from about 82% to about 88% by weight of the polypropylene homopolymer and about 12% to about 18% of the ethylene/propylene random copolymer.

Polypropylene homopolymers that are suitable to be used in the compositions according to the current invention have a crystalline content preferably of at least 55%, as determined by annealed Differential Scanning Calorimetry (ADSC) and a xylene solubles content less than about 3%, preferably less than about 2%. Xylene solubles (XS) and insolubles (XIS) were determined by ASTM method D-5492. Examples include, but are not limited to: D022D, F020HC and F050HC from Sunoco, 3576X, PPH4025, 3365 and 3281 from TotalFina, 5A28 from Dow, 6219, 1012, HB3252 and 9433x from BPAmoco, Adstiff HA722J from Basell, PP1042 from ExxonMobil, Marlex HGX-030 and HGX-040 from Phillips Sumika. The ethylene/propylene RCPs that are suitable for use in the resin compositions according to the current invention contain from about 0.5% to about 7% of ethylene, preferably about 2.5% ethylene. Ethylene content is determined using ¹³C NMR. Examples of ethylene/propylene copolymers include, but are not limited to: TR3020F, TR3005, TR3020SF from Sunoco, DD20 and 6D65L from Dow, 8573, 6232, 6253, 7450HC, 7231X, 8453 and Z9450 from TotalFina, 8249, KB4105, 8244, KB5180 and KB4285 from BPAmoco, PP9852E1 from ExxonMobil, Marlex RGX-020 from Phillips Sumika, and SR256M and SR257M from Basell.

The resin compositions according to the current invention can be produced by melt blending a low solubles high crystallinity polypropylene homopolymer, such as those listed above, with an ethylene/propylene copolymer, such as those listed above, by compounding in a known way. However, preferably, the resin compositions according to the current invention are produced in situ in a multi reactor process. For example, in a four reactor process, the polypropylene homopolymer may be produced in the first two reactors, the first stage. The ethylene/propylene RCP may then be produced in the third and fourth reactors, the second stage, as the homopolymer continues to polymerize. Alternatively, in a two reactor process, the polypropylene homopolymer is made in the first reactor and the ethylene/propylene RCP may be made in the second reactor as the homopolymer continues to polymerize. In this way, the ethylene/propylene RCP may be distributed more uniformly in the blend. Although production of the blends by an in-reactor process is preferred, blends made by either method are suitable for producing BOPP films according to the current invention. The in-reactor process provides better dispersion of the random copolymer in the homopolymer versus the melt blending process. The in-reactor blending process also allows for more efficient usage of reactor capacity since both stages of a two-stage reactor train are utilized, as opposed to just the first stage, which is standard practice in making a pure homopolymer. This also provides higher production rates of the polymer blend.

For non-woven fabrics applications it is preferred that an in-reactor blend be produced having a melt flow rate suitable for spunbond or meltblown processing without the need for vis-breaking. Techniques for controlling melt flow rate during polymerization are known to those having skill in the art. However, vis-breaking of a low melt flow reactor blend is within the scope of the present invention.

The resin compositions, non-wovens and BOPP films according to the current invention may also include a number of additives, including but not limited to: nucleators, anti-oxidants, acid neutralizers, slip agents, antiblock, antifogging agents and pigments.

Example 1 Conventional Polypropylene in BOPP Film

Several samples of a resin blend according to the current invention were prepared using a conventional non-BOPP grade polypropylene homopolymer having low solubles. Polypropylene homopolymer, D022D, available from Sunoco, was melt blended with various amounts of a random copolymer resin having 2.5% ethylene, TR3020F, available from Sunoco. A commercial BOPP grade polypropylene, FF020D, available from Sunoco, containing relatively large amounts of xylene solubles, e.g., 4.9%, was included for comparison. The various blends prepared are shown in Table 1.

TABLE 1 Compositions Prepared Resin A B C D E F D022 100 95 90 80 TR3020 5 10 20 100 FF020D 100

The melt flow rate (MFR) and the contents of xylene soluble were determined by the method prescribed in ASTM 1238 and 5492, respectively. The molecular weights were determined by high temperature size exclusion chromatography (HSEC) at 140° C. For thermal characteristics, DSC (Differential Scanning Calorimetry) thermograms were recorded, where polymer was melted at 230° C. for 5 minutes and cooled to 0° C. at a rate of 10° C./min while the recrystallization exotherm was recorded. Then, the sample was heated to 190° C. at a rate of 10° C./min in order to record the melting endotherms. The heat of recrystallization was used to estimate the overall crystallinity (% Xc) of ICP. The characteristics of compounds containing random copolymer along with homopolymers and random copolymer are given in Table 2.

TABLE 2 Characteristics of compounds containing RCP in comparison to FF020D Property A B C D E F D022 100 95 90 80 TR3020 5 10 20 100 FF020D 100 (30H036) MFR 2.0 1.8 1.8 1.8 2.4 2.0 % XS 2.9 2.9 3.1 3.3 5.2 4.9 Mn/1000 64 64.9 65.0 65.7 65.9 66.0 Mw/1000 333 330 328 322 296 349 Mz/1000 930 912 917 874 751 1045 D 5.22 5.08 5.05 4.91 4.49 5.28 T_(m)(° C.) 164.8 164.8 163.1 162.9 149.2 — T_(c)(° C.) 115.0 112.5 112.1 112.0 103.4 — % X_(c) 58.7 57.3 57.5 56.3 45.6 53.9 Samples contain 0.15% Irgafos 168, 0.1% Irganox 1076, 0.1% Irganox 1010 and 0.025% DHT

It is known that the isotacticity of the insoluble fraction of polypropylene and the amounts of solubles are inversely related and determine the crystallinity of the polymer. Thus, a random copolymer (RCP) that has relatively lower crystallinity with larger amounts of xylene solubles than a homopolymer could modify (or decrease) the overall crystallinity when added to homopolymer. Table 2 indicates that the addition of RCP slightly increases the amounts of xylene solubles, decreases the overall crystallinity and the recrystallization temperature. Addition of 20% RCP was not, however, enough to decrease the overall crystallinity of the compound to the same level as that of the standard BOPP grade polypropylene. Based on the additive rule, it appears that about 40% RCP is required to have a comparable overall crystallinity to FF020D.

Cast Sheet and T.M. Long Films

Cast sheets 22-23 mil thick were prepared from these materials in Table 2 using HPM sheet line (L/D=30) under the conditions shown in Table 3. The extruder was equipped with a flat die for vertical extrusion. The polymer melt extruded through the die was quenched onto a chill roll into the sheet. The temperature of the chill roll was kept at 110° F. (43.3° C.).

TABLE 3 Zone 1 2 3 4 Die 1 Die 2 Melt Temp. Temp. (° C.) 204 246 260 260 260 260 263

The density of the extruded sheets was measured in a Techne Density column containing 558 ml H₂O and 322 ml isopropanol mixture in the heavy flask and 327 ml H₂O and 553 ml isopropanol in the light flask.

For film preparation, polypropylene was extruded onto a cast roll to produce either 0.254 or 0.508 mm thick sheet. Samples (5.08 cm×5.08 cm) were cut out of the sheet stock and stretched with a T.M. Long stretcher (T.M. Long Corporation, Somerville, N.J.). This equipment allows simultaneous and/or consecutive biaxial orientation at an elevated temperature. Samples were stretched with the T.M. Long at a given stretching temperature and a fixed strain rate of 50.8 mm/sec after 25 sec. pre-heating. The tensile biaxial stress-strain curve is simultaneously generated during orientation. The sheets were stretched to 0.6-0.7 mil film by simultaneous stretching at 6.2×6.2 draw ratio. The film properties were determined by the method prescribed in ASTM 882. Table 4 gives the density of the cast sheet, T.M. Long yield stress and film properties while FIGS. 1 and 2 show the dependence of T.M. Long yield stress on the stretching temperature and the cast sheet density, respectively. In accordance with the overall crystallinity of the compound, the density of the cast sheet also decreases with increasing amounts of RCP. The T.M. Long yield stress decreases with increasing stretching temperature and/or with decreasing the density of the cast sheet as shown in FIGS. 1 and 2.

TABLE 4 Density of sheet stock and T.M. Long yield stress 667A 667B 667C 667D 667E 884A Resin Composition D022 5% RCP 10% 20% TR3020 FF020D RCP RCP (30H036) Density (cast sheet) 0.9028 0.9025 0.9017 0.9017 0.8957 0.8988 TML yield stress (psi) @ 138° C. 505 494 486 458 125 404 @ 143° C. 377 390 378 319 38 294 @ 149° C. 258 251 234 199 — 174

It is noted that FF020D that has 4.9% xylene solubles exhibits about 100 psi lower T.M. Long yield stress than D022 that has 2.9% xylene solubles irrespective of the stretching temperature. TR3020 that has 2.5% ethylene and 5.5% xylene solubles has significantly lower T.M. Long yield stress than FF020D. It can be attributed to the lower melting temperature and overall crystallinity of the random copolymer along with larger amounts of xylene solubles than the homopolymer. These results indicate that the crystalline state at the stretching temperature dictates the T.M. Long yield stress. It should be noted that the crystalline state of a polypropylene at a stretching temperature predominantly affects the viscosity of the “pseudo-melt” (because the polymer is partially melted) along with molecular weight. Table 5 gives the properties of film produced with T.M. Long stretcher. These results indicate that the tensile properties and haze of the compounds are comparable to those of homopolymer, i.e., FF020D, even at 20% addition of random copolymer. These results indicate that the homo-random polypropylene can be employed as an alternative BOPP material replacing high solubles homopolymer.

TABLE 5 Properties of film produced at 138° C. by stretching at 6.2 × 6.2 ratio 667A 667B 667C 667D 667E 884A Resin Composition D022 5% RCP 10% 20% TR3020 FF020D RCP RCP (30H036) Tensile Stress (kpsi) 27.1 31.4 31.1 30.3 21.9 27.1 Tensile Strain (%) 63.2 70.2 72.4 74 59.9 69 Modulus (kpsi) 367 370 370 254 363 332 Haze 0.63 0.63 0.68 0.63 0.67 0.65

Example 2 High Crystalline Polypropylene in BOPP Film

A second set of compositions was prepared using a high crystallinity polypropylene homopolymer, F050HC, available from Sunoco. The random copolymer, TR3005, available from Sunoco, having 2.5% ethylene, was melt blended with the HC homopolymer via compounding as given in Table 6. A conventional BOPP material, FF029A, available from Sunoco, designed for the core material of clear film, was used as a control.

TABLE 6 Compounds prepared in this study 2100944 A B C D F050HC % 100 85 70 TR3005 % 15 30 FF029A (31J026) 100

The melt flow rate (MFR) and the contents of xylene soluble were determined by the method prescribed in ASTM 1238 and 5492, respectively. The molecular weights were determined by high temperature size exclusion chromatography (HSEC) at 140° C. The melting temperature and recrystallization temperature for each composition was determined using annealed differential scanning calorimetry (ADSC). The polymers were melted at 230° C. for 5 minutes and cooled to 0° C. at a rate of 10° C./min while recording recrystallization exotherm. Then, the sample was heated to 190° C. at a rate of 10° C./min to record the melting endotherms. The heat of recrystallization was used to estimate the overall crystallinity (% Xc) of ICP.

The materials were also evaluated by thermal fractionation. The polymer melt was cooled to 170° C. at a rate of 20° C./min, followed by isothermal crystallization process during which the sample was held for 4 hours. The isothermal crystallization process continued to decrease to 130° C. at 10° C. decrement. The temperature of the sample was then decreased to 0° C., and the sample was analyzed as it was heated to 200° C. at a rate of 10° C./min. to record the melting endotherm. It has been discovered that how well a material stretches on a tenter frame depends on the shape of endotherm recorded from the thermal fractionation. Thus, the thermal behavior of the compositions produced were evaluated via the thermal fractionation method as shown in FIG. 3. As can be seen, the blend with 30% of RCP has a trace similar to that of the standard BOPP grade material.

The characteristics of materials produced are given in Table 7. The commercial BOPP grade, FF029A that contains relatively large amounts of xylene solubles, e.g., 5.8%, was included for comparison. As noted in the previous Example (1), a RCP that has 2.5% ethylene has relatively lower crystallinity and larger amounts of xylene solubles than a homopolymer. Therefore, when added to homopolymer, a RCP should modify, i.e., decrease, the overall crystallinity. Table 7 confirms that the addition of RCP to a homopolymer slightly increases the amounts of xylene solubles, decreases the overall crystallinity and the recrystallization temperature. It is noted that the blend of F050HC with 30% TR3005 has a slightly higher crystallinity than FF029A. The molecular weight and distributions of all the polymers are comparable within the limit of experimental error.

TABLE 7 Characteristics of compounds containing RCP in comparison to FF029A 2100944 D A B C FF029A F050HC 15% TR3005 30% TR3005 (31J026) MFR 6.2 4.6 3.7 3.0 % XS 1.73 2.28 3.12 5.82 T_(m)(° C.) 163.7 162.2 159.3 159.1 T_(C)(° C.) 118.1 115.1 112.9 112.6 % X_(c) 61.9 58.6 55.2 53.3 Mn/1000 53.5 63.2 65.8 50.4 Mw/1000 252 278 283 257 Mz/1000 779 819 838 988 D 4.7 4.4 4.3 5.1 Samples contain 0.15% Irgafos 168, 0.1% Irganox 1076, 0.1% Irganox 1010 and 0.025% DHT Cast Sheets and T.M. Long Films

As in Example 1, cast sheets 22-23 mil thick were produced using HPM sheet line (L/D=30) under the conditions in Table 8.

TABLE 8 Zone 1 2 3 4 Die 1 Die 2 Melt Temp. Temp. (° C.) 204 246 260 260 260 260 263

The temperature of the chill roll was kept at 110° F. (43.3° C.). The density of the extruded sheets was measured in a Techne Density column containing 558 ml H₂O and 322 ml isopropanol mixture in a heavy flask and 327 ml H₂O and 553 ml isopropanol in a light flask.

The 22-23 mil sheets were stretched to 0.6-0.7 mil film by simultaneous stretching at 6.2×6.2 draw ratio with T.M. Long after 25 sec. pre-heating at a given stretching temperature. The yield stress was measured while stretching the cast sheet.

The film tensile properties were determined by the method prescribed in ASTM 882.

Strips (1″×8″) from T.M. Long film were used to determine the tensile properties. Although ASTM recommends 10″ grip separation and 1 in/min crosshead speed for the measurement of tensile modulus, 4″ grip separation was employed due to the size of the T.M. Long film. Accordingly, the crosshead speed was adjusted to 0.4 in/min. For all other tensile properties, the crosshead speed was 2 in/min. At least 5 specimens were tested.

Optical properties such as transparency, haze and clarity of the film were evaluated by the method prescribed in ASTM 1003 (Haze and % transmittance) and ASTM 1746 (clarity).

Gloss was measured at the 3 different angles, 20, 45 and 60 degree by using the method described in ASTM 2457, where 60-deg. is recommended for intermediate gloss films, 20-deg. for high gloss films and 45-deg. for intermediate and low gloss films.

Shrinkage was measured using ASTM D-2732. A rectangular cutout (3.9″×3.9″) from the T.M. Long film was placed in a “Free Shrink” holder such that the cutout is free from contact with the edge of the holder. Then, the holder was immersed in an oil bath for at least 10 seconds at a given temperature in order for the material to come to thermal equilibrium and undergo maximum shrinkage. The holder was removed from the oil bath and quickly immersed in oil at room temperature. After at least 5 seconds, the sample was removed from the oil. After removing the remaining oil from the specimen, the dimension of the specimen was measured and the shrinkage was calculated using the equation: % shrinkage=(L _(o) −L _(f))/L _(o)×100 where L_(o) is the initial length and L_(f) length after shrinking

Table 9 gives the density of the cast sheet, the T.M. Long yield stress and film properties while FIGS. 4 and 5 show the dependence of the T.M. Long yield stress on the stretching temperature and the cast sheet density, respectively.

TABLE 9 Density of sheet stock and T. M. Long yield stress B C A 15% 30% D Resin Composition F050HC TR3005 TR3005 FF029A Density (Cast Sheet)  0.9043  0.9034  0.9026  0.9029 T. M. Long yield stress @ 138° C. 779^(a) 644 549 519 @ 143° C. 594 496 418 390 @ 149° C. 445 365 281 253 ^(a)the film tore during stretching after yield.

In accordance with the overall crystallinity of the materials, the density of the cast sheet decreases with increasing amounts of RCP as does the T.M. Long yield stress as shown in FIGS. 4 and 5. While the T.M. Long film of FF050HC tore after yielding when stretched at 138° C., the blend containing 15% random copolymer did not tear when stretched. It is noted that although the blend that contains 30% random copolymer has a slightly lower density than FF029A, its T.M. Long yield stress is higher as shown in FIG. 5. Since the T.M. Long yield stress depends on the density, i.e., crystallinity, of the cast sheet at the stretching temperature, it appears that the blend containing 30% random copolymer should have a higher density at the stretching temperature than FF029A does.

The properties of film produced at 3 different temperatures with a T.M. Long stretcher are given in Table 10 and depicted in FIGS. 6-11. The results in Table 10 may be summarized as follows. The T.M. Long films produced from the blends exhibit higher tensile properties than those produced from FF029A. Haze and % transmittance of the film produced from the blends at 138° C. and/or 143° C. are comparable to those produced from FF029A. However, when stretched at 149° C., the film produced from FF029A is much hazier than those from the blends. The 45-degree gloss varies depending upon the stretching temperature. The shrinkage of the film from the blends is slightly less than that from FF029A.

TABLE 10 Properties of T. M. Long film produced at various temperatures 2100944 A B C D F050HC^(a) 15% TR3005 30% TR3005 FF029A 138° C. Haze — 0.90 0.58 0.63 Transmittance (%) 94.5 94.4 94.5 Clarity — 97.4 98.1 98.0 Gloss 20 — 36.1 27.2 41.0 45 — 93.1 90.3 93.7 60 — 129.7 114.2 114.2 Tensile stress (kpsi) — 31.6 32.4 33.4 Tensile strain (%) — 68.6 70.0 72.0 Modulus (kpsi) — 524 471 448 Shrinkage (%) — 17.5 19.9 19.5 143° C. Haze — 0.72 0.77 0.61 Transmittance (%) 91.9 92.6 92.2 Clarity — 97.8 97.4 98.9 Gloss 20 — 47.1 89.4 84.3 45 — 86.2 86.2 91.7 60 — 127.2 126.3 126.4 Tensile stress (kpsi) 33.4 35.6 33.4 32.3 Tensile strain (%) 75.0 77.3 80.0 72.1 Modulus (kpsi) 601 579 561 496 Shrinkage (%) — 16.16 19.65 18.17 149° C. Haze 1.58 2.63 2.5 6.08 Transmittance (%) 91.2 90.9 91.1 87.2 Clarity 95.3 90.5 91.3 87.1 Gloss 20 44.5 67.1 47.3 46.7 45 88.9 85.8 86.3 79.3 60 113.9 114.4 109.1 103.8 Tensile stress (kpsi) 29.5 27.2 29 24.7 Tensile strain (%) 83.6 65 81.5 66 Modulus (kpsi) 536 470 521 356 Shrinkage (%) 8.3 10.1 9.1 10.1 ^(a)film broke after yield when stretched at 138° C.

Example 3 In-Reactor Blending

Polypropylene homopolymer was continuously produced at 70° C. in a first stage polymerization using two loop reactors by using a catalyst system (catalyst, co-catalyst and external donor) that provides relatively high isotacticity, followed by production of 10-20 wt % random copolymer containing 2.5 wt ethylene in a second stage gas phase reactor. The propylene monomer was fed the loop reactors at a rate of 80 kg/h while maintaining 700 ppm H₂ and the density of 560 g/l. The homopolymer was continuously transferred to the second stage gas phase reactor where the random copolymer was produced. To produce the random copolymer, both ethylene and propylene at 0.03 mol % gas phase ratio (C2/C2+C3) and 0.015 mole % H₂ were fed to the gas phase reactor. The characteristics of the in situ polymer blend produced in the continuous reactor are given in Table in comparison to a HCPP. Table 11 indicates that the HCPP/RCP blend produced in-situ contains 12 wt % random copolymer and less than 2 wt % XS.

TABLE 11 Characteristics and Properties of in situ blend and HCPP homopolymer LIMS # HCPP Blend % RCP 0  12* MFR 1.2  2.8 % XS 1.68   1.87 C2 - total 0  0.3 — XIS XS C2 — 0.17 9.31 Mn/1000 — 63.5 51.8 Mw/1000 — 311 124 Mz/1000 — 1097 437 D — 4.9 2.4 T_(m) (° C.) 167 166.6 Tc(° C.) 119.6 117.3 % X_(C) 59.8  57.2 Flex modulus (kpsi) 272 249  TS @Y (psi) 5519 5364   *estimated based on ethylene content.

Example 4 Non-Woven Fabrics

Spunbond fabrics were produced using an in-reactor blend of a highly crystalline propylene homopolymer and a random copolymer (HCPP/RCP), a mini-random copolymer (mini), a random copolymer (RCP), and a standard spunbond grade propylene homopolymer (CP). A melt flow rate of 35 dg/min for spunbond processing was obtained by visbreaking a reactor produced highly crystalline propylene homopolymer and random copolymer having a starting melt flow rate of about 3 dg/min. The comparison mini-random and random copolymers were also visbroken to a melt flow rate of about 35 dg/min. The properties of the materials used in this example are set forth in Table 12 below. Values reported for the HCPP/RCP blend, mini-random copolymer and random copolymer are for the visbroken materials.

TABLE 12 Materials used for Spunbond Processing Mini-Random Random Std. Spunbond HCPP/RCP In- Copolymer Copolymer Polypropylene Reactor Blend (visbroken) (visbroken) CP360H (visbroken) FT021 TR3020 % Xc 60.6 59.1 53.7 46.5 T_(m)(° C.) 163.6 162.8 157.3 147.1 T_(c)(° C.) 112 113.3 109.3 104.4 % XS 1.81 1.88 4.78 5.58 % mmmm - XIS 96.97 94.92 92.44 86.34 % C₂ 0 0.7 0.7 2.7

Spunbond fabrics were produced on a Reifenhauser Reicofil II slot draw line using a 2734-hole die. In order to achieve the target denier in the bonded fabrics, the suction and cooling fans were adjusted to modify the draw force. The deniers of the fabrics were measured using an optical microscope. The fabrics were produced at a series of calendar temperatures for each polymer used.

The tensile strength of the fabrics produced was measured in both the machine direction (MD) and transverse direction (TD) using ASTM method D-5035, “strip force” tensile break strength. Tensile strength in the machine and transverse directions was used as a measure of the bonding window for each polypropylene, which is defined as the range of calendar temperature over which a fabric exhibits a tensile strength at least 90% as high as its maximum measured tensile strength. FIGS. 12( a) and 12(b) depict the tensile strength of the spunbond fabrics produced in the machine direction and transverse direction respectively. The curves in FIGS. 12( a) and 12(b) illustrate the approximated width of the 90% bonding window for each fabric tested. These data indicate that the bonding window for the blend according to the current invention is comparable to the standard spunbond grade polypropylene, and slightly narrower than that of the mini-random copolymer.

Additional properties tested for the fabrics produced are depicted in FIGS. 13( a), 13(b) and 13(c). FIG. 13( a) illustrates the trapezoid tear strength of fabrics produced as measured by comparison of the MD and TD tensile strength. As can be seen from the figure, the blend according to the current invention provides greater balance between the MD and TD tensile strength. FIG. 13( b) illustrates the flexural rigidity of fabrics produced in the example. Again, the data indicate the fabrics produced with blends according to the invention display a better balance of rigidity in the machine and transverse directions. FIG. 13( c) depicts the coefficient of friction (COF) for the fabrics produced. Coefficient of friction is used as a measure of the softness of a fabric. The data in FIG. 13( c) indicate that fabrics produced from blends according to the invention display a softness equivalent to fabrics produced from a 2.7% ethylene content random copolymer, while having superior tensile properties.

A second set of samples of spunbond fabric were produced from an in-reactor blend of highly crystalline propylene homopolymer and random copolymer according to the invention (HR), and a standard spunbond grade polypropylene (CP). The properties of the polymers are shown in Table 13.

TABLE 13 Materials used for Spunbond Processing HCPP/RCP Blend Std. Spunbond Grade (visbroken) % Xc 61.8 57.4 T_(m)(° C.) 163.3 161.4 T_(C)(° C.) 113.4 112.5 % XS 1.81 2.99 % mmmm - XIS 96.14 92.28 % C₂ 0 0.7

Spunbond fabrics were again produced on a Reifenhauser Reicofil II slot draw line using a 2734-hole die. The fabrics were tested for tensile strength in both the machine and transverse directions. The bonding curves for the two materials are shown in FIG. 14. The estimated bonding windows from FIG. 14 shows that the blend according to the current invention has a broader bonding window than the standard spunbond grade material.

The examples provided demonstrate that the addition of RCP to a homopolymer, which has relatively small amounts of xylene solubles and is not easily stretchable, facilitates the stretchability of the homopolymer. Thus it is possible to replace standard high solubles BOPP grade polypropylene homopolymers with lower solubles content materials. This is especially advantageous to produce a stiffer film since a high crystalline PP can be modified to be stretchable under the conventional processing conditions. Further, the films produced from the blend containing RCP exhibit improved properties over films produced with standard BOPP grade polypropylene.

The examples also demonstrate that the blends according to the current invention perform as well as standard grade polypropylenes in non-woven fabric manufacturing, and provide fabrics having improved balance of properties in the MD and TD directions, and better softness.

The present invention has thus been described in general terms with reference to specific examples. Those skilled in the art will recognize that the invention is not limited to the specific embodiments disclosed in the examples. Those skilled in the art will understand the full scope of the invention from the appended claims. 

What is claimed is:
 1. A non-woven fabric comprising at least one layer of fibers including a reactor blended polypropylene copolymer, the polypropylene copolymer comprising about 70% to about 95% by weight of a polypropylene homopolymer, said polypropylene homopolymer having less than 3% by weight xylene solubles and a crystallinity of at least 55%; and about 5% to about 30% by weight of an ethylene/propylene copolymer, said ethylene/propylene copolymer containing from about 0.5% to about 15% ethylene by weight, wherein the at least one layer of fibers is a spunbond or a meltblown fabric layer.
 2. The non-woven fabric according to claim 1, wherein the polypropylene copolymer comprises about 70% to about 85% by weight of the propylene homopolymer, and about 15% to about 30% by weight of the ethylene/propylene copolymer.
 3. The non-woven fabric according to claim 2, wherein the polypropylene copolymer comprises about 82% to about 88% by weight of the polypropylene homopolymer and about 12% to about 18% of the ethylene/propylene random copolymer, and the ethylene/propylene random copolymer has an ethylene content of from 2% to 4% by weight.
 4. The non-woven fabric according to claim 2, wherein the ethylene/propylene random copolymer contains from about 2.0% to about 4.0% ethylene by weight.
 5. A non-woven fabric comprising at least one layer of fibers including a reactor blended polypropylene copolymer, the polypropylene copolymer comprising about 70% to about 95% by weight of a polypropylene homopolymer, said polypropylene homopolymer having less than 3% by weight xylene solubles and a crystallinity of at least 55%; and about 5% to about 30% by weight of an ethylene/propylene copolymer, said ethylene/propylene copolymer containing from about 0.5% to about 7.0% ethylene by weight, wherein the at least one layer of fibers is a spunbond fabric layer.
 6. The non-woven fabric according to claim 5, wherein the polypropylene copolymer comprises about 70% to about 85% by weight of the propylene homopolymer, and about 15% to about 30% by weight of the ethylene/propylene copolymer.
 7. The non-woven fabric according to claim 6, wherein the polypropylene copolymer comprises about 82% to about 88% by weight of the polypropylene homopolymer and about 12% to about 18% of the ethylene/propylene random copolymer, and the ethylene/propylene random copolymer has an ethylene content of from 2% to 4% by weight.
 8. The non-woven fabric according to claim 5, wherein the ethylene/propylene random copolymer contains from about 2.0% to about 4.0% ethylene by weight.
 9. A non-woven fabric comprising at least one layer of fibers including a reactor blended polypropylene copolymer, the polypropylene copolymer comprising about 70% to about 95% by weight of a polypropylene homopolymer, said polypropylene homopolymer having less than 3% by weight xylene solubles and a crystallinity of at least 55%; and about 5% to about 30% by weight of an ethylene/propylene copolymer, said ethylene/propylene copolymer containing from about 0.5% to about 7.0% ethylene by weight, wherein the at least one layer of fibers is a meltblown fabric layer.
 10. The non-woven fabric according to claim 9, wherein the polypropylene copolymer comprises about 70% to about 85% by weight of the propylene homopolymer, and about 15% to about 30% by weight of the ethylene/propylene copolymer.
 11. The non-woven fabric according to claim 10, wherein the polypropylene copolymer comprises about 82% to about 88% by weight of the polypropylene homopolymer and about 12% to about 18% of the ethylene/propylene random copolymer, and the ethylene/propylene random copolymer has an ethylene content of from 2% to 4% by weight.
 12. The non-woven fabric according to claim 9, wherein the ethylene/propylene random copolymer contains from about 2.0% to about 4.0% ethylene by weight.
 13. The non-woven fabric according to claim 1, wherein the ethylene/propylene copolymer contains from about 7.0 to about 15% ethylene by weight. 